Apparatus for producing tile panels



6 Sheets-Sheet l R. W JOHNSON 1 7 l l i APPARATUS FOR PRODUCING TILFPANI. S

j: "Uf fff l i i l lirl l i l Jan. 20, 1970 Original Filed Sept.

Jan. 20, 1970 R. W. JOHNSON 3,490,096

APPARATUS FOR PRODUCING TILE PANELS Original Filed Sept. 29, 1964 6Sheets-Sheet 2 Jan. 20, 1970 R. W. JOHNSQN 3,490,096

APPARATUS FOR PRODUCING TILE PANELS Original Filed SeptA 29, 1964 6Sheets-Sheet 5 Jan. 20, 1970 R. W. JoHNsoN APPARATUS FOR PRODUCING TILEPANELS 6 Sheets-Sheet 4.

Original Filed Sept. 29. 1964 I l I p M mf V WM I g /90a7 /63 Jan. 20,1970 R. W. JOHNSON APPARATUS FOR PRODUCING TILE PANELS Original FiledSept. 29. 1964 6 Sheets-Sheet 5 Jan. 20, 1970 R. w. .JOHNSON 3,499,996

APPARATUS FOR PRODUCING TILE PNELS Original Filed Sept. 29, 1964 6Sheets-Sheet 6 United States Patent O 3,490,096 APPARATUS FOR PRODUCINGTILE PANELS Russell W. Johnson, Hutchinson, Minn., assgnor of fiftypercent to Clarence R. Enright, St. Cloud, Minn. Original applicationSept. 29, 1964, Ser. No. 400,149, now Patent No. 3,359,354, dated Dec.19, 1967. Divided and this application Dec. 1, 1967, Ser. No. 739,979

Int. Cl. B29c 1/14 U.S. Cl. 18-5 35 Claims ABSTRACT F THE DISCLOSUREApparatus for producing finished tile panels made up of spaced tilepieces and a cured resin mixture binding said pieces that in oneembodiment includes a tile mounting platform having a resilientlymounted alignment frame, a vacuum manifold for picking up aligned tilepieces and a support member whereby applying a vacuum, the resin mixtureis drawn into the space between the tile pieces, the support member andmanifold. In lanother embodiment there is chain conveyor mechanism foraligning tile pieces and a vacuum manifold that is indexed throughvarious steps during the panel making operation. In another embodimentthe manifold is moved to pick up tile pieces, then retracted androtated, and thereafter a heated platen advanced to be above themanifold where the resin mixture is drawn between the tile pieces.

This is a division of application Ser. No. 400,149, tiled Sept. 29,1964.

This invention relates to a new and novel apparatus for forming rigid orsemi-rigid finished tile panels that in part are made up of a pluralityof individual pieces of ceramic tile.

An additional object of this invention is to provide new and novelpneumatic apparatus utilizable in producing finished tile panels.Another object of this invention is to provide new and novel manifoldapparatus for use in producing preformed tile panels.

The invention is illustrated by reference to the drawings in whichcorresponding numerals refer to the same part and in which:

FIGURE l is a vertical cross-section of the tile mounting board and thetile arraying frame with individual ceramic tile pieces and said frameshown in perspective, portions of said View being broken away;

FIGURE 2 is a fragmentary vertical corss-sectional view shown inperspective of one corner portion of the tile aligning platform, and thetile mounting board with tile pieces arrayed thereon, a portion of saidplatform being broken away;

FIGURE 3 is a bottom view of the manifold assembly of this inventiongenerally taken along the line and in the direction of the arrows 3-3 ofFIGURE 4, longitudinal and transverse portions of said assembly beingbroken away;

FIGURE 4 is a fragmentary vertical cross-sectional view of the structureof FIGURE 2 and the vacuum manifold assembly illustrating the manifoldassembly just as it has been suiiiciently lowered to place the resilientpad in uid sealing relationship with the tile pieces, the view of themanifold assembly being broken away in part, and in cross-sectiongenerally taken along the line and in the direction of the arrows 4 4 ofFIGURE 3. Also illustrated in schematic are pneumatic circuitry andcomponents that are connected to said assembly;

FIGURE 5 is an enlarged fragmentary cross-sectional view of a portion ofthe structure of FIGURE 4 other than it illustrates the relativepositions of portions of said structure after full application of vacuumhas been applied to the manifold chamber;

FIGURE 6 is a plan of the heat transfer support member with the resinmixture pattern board thereon and resin mixture filling the pattern;

FIGURE 7 is an enlarged, fragmentary, vertical crosssectional viewgenerally taken along the line and in the direction of the arrows 7-7 ofFIGURE 6;

FIGURE y8 is a fragmentary vertical cross sectional view of the supportmember of FIGURE 6 after the manifold assembly has been fully loweredand the resinous material has been drawn into the voids between the tilepieces.

FIGURE 9 is an enlarged fragmentary vertical view generally taken alongthe line in the direction of the arrows 9-9 of FIGURE `8 to illustratethe lands of manifold assembly side rails in abutting relation with theheat transfer support member;

FIGURE 10 is a fragmentary cross-sectional view in perspective of afinished tile panel made with the apparatus of FIGURES 1-9;

FIGURE 11 is an enlarged fragmentary, vertical crosssectional view of asecond embodiment of a vacuum manifold assembly and a tile mountingboard showing the manifold assembly just as it has been sufiicientlylowered to place a manifold spool in abutting relationship with a tilepiece;

FIGURE 12 is a fragmentary vertical cross-sectional view, part inperspective, of the structure of FIGURIE 1l just after the manifoldassembly has been fully lowered to illustrate the title pieces andmanifold spools before a vacuum is applied to the manifold chamber,portions of said manifold assembly being broken away;

FIGURE 13 is an enlarged fragmentary cross-sectional view correspondingto FIGURE l1 other than it is taken of the structure in the FIGURE 12position after full vacuum has been applied to the manifold chamber;

FIGURE 14 is a fragmentary cross-sectional view taken somewhat inperspective to illustrate the picked up tile pieces of FIGURE 13positioned above the heat transfer support member and after the resinousmaterial has been drawn into the voids between the tile pieces;

FIGURE 15 is a fragmentary perspective view of the finished panel madeby the method and apparatus of FIGURES 11-l-4 showing the finishedsurface thereof;

FIGURE 16 is a view similar to FIGURE 15 other than it illustrates thegridded back surface of the finished panel of FIGURE 15;

FIGURE 17 is a diagrammatic vertical view of a part of a continuousprocess for forming the finished tile panels of this invention;

FIGURE 18 is a diagrammatic plan view of the structure for carrying saidcontinuous process including the structure illustrated in FIGURE 17;portions of the vacuum manifold assembly being broken away to illustratethe structure therebeneath and other positions of the manifold assemblybeing illustrated in dotted lines.

FIGURE 19 is an enlarged fragmentary plan view of the mechanism forcontinuously aligning individual tile pieces in accordance with theprocess of FIGURES 17 and 18, portions of said view being broken away;

FIGURE 20 is a fragmentary enlarged perspective view of one cornerportion of the chute and the continuous belt of FIGURE 19 for aligningtile, portions of the tile pieces being broken away to more clearlyillustrate the invention;

FIGURE 2l is a plan view, portions being diagrammatic, of a furtherembodiment of apparatus for making finished tile panels of thisinvention, said view showing the assemblies thereof in a datumcondition;

FIGURE 22 is a side elevational view of the apparatus of FIGURE 2l, saidview being generally taken along the line and in the direction of thearrows 22-22 of FIGURE 2l;

FIGURE 23 is an enlarged fragmentary cross sectional view generallytaken along the line and in the direction f the arrows 23-23 of FIGURES21 and 22 to illustrate the structure mounting the manifold assembly forrotational and vertical transitory movement, said view showing themanifold assembly in a lowered datum condition;

FIGURE 24 is a view similar to FIGURE 23 other than it illustrates themanifold assembly in an elevated condition and the alignment assemblytranslated to beneath the manifold assembly prior to the lowering of themanifold assembly to pick up tile pieces; and

FIGURE 25 is a view similar to FIGURE 23 other than the manifoldassembly has been rotated 180 about a horizontal axis and the steamheated platen has been horizontally moved to a position directly abovesaid manifold assembly.

Referring to FIGURE l there is illustrated a gridded tile mounting boardpositioned on the constant temperature vi-bratory frame mechanism,generally designated 11. The tile mounting board has a generally planarsurface other than for the integrally formed upwardly extending parallellongitudinal grids 13 and parallel transversely extending grids 14 thatintersect grids 13. The grids 13 and 14 are of a size and shape toretain the individual tile pieces 16 in the ultimate desired spacedrelationship of a preformed tile panel of this invention. Preferably themounting board 10 is made of a poly-ester polyurethane resinousmaterial, such as Du Ponts Adiprenen, that has been treated to beslippery by the addition of molydenum compounds.

In order to facilitate arraying the tile piece 16 on the tile mountingboard, the tile mounting board, the tile mounting board is positioned onthe vibratory frame mechanism 11. The mechanism 11 includes a constanttemperature vibratory base 12 that is vibrated in a horizontal plane bya vibrator 17. The vibrator imparts vibratory components of motion inyboth longitudinal and transverse horizontal directions as indicated bythe double arrows 18.

The base 12 has a perimetric shoulder 12a that mounts an upwardlyextending open rectangular frame 19 that extends above the base adistance substantially greater than the thickness of the tile piece plusthe thickness of the tile mounting board 10. The central opening of theframe 19 is of a size and shape to form a close t with the board 10', itbeing noted that there are no grids 13 and 14 formed at the perimetricedges of the board 10.

After the tile pieces have been arrayed by the structure of FIGURE l aswill be more fully explained hereinafter, the tile mounting board 10with the tile pieces thereon is removed from the vibratory mechanism 11and positioned on the aligning platform which is generally designated 25and in part illustrated in FIGURE 2. The platform 25 includes a mountingplate 26 that has attached to the upper surfaces thereof a constanttemperature base 27. The base 27 in horizontal cross section is of thesame size and shape as the tile mounting board, but is less than onehalfthe area of the mounting plate 26.

Mounted on the mounting plate 26 to be vertically spaced thereabove andto surround a tile mounting board positioned on the base 27 is an openrectangular aligning frame 28 having a central opening of a size andshape so that the inner vertical edges of said frame form a close t withthe virtial edges of the tile mounting board. The aligning frame isprovided with a plurality of vertical bores 28a, the upper portion ofsaid bores being enlarged to receive the cap portion of cap bolts 29.The reduced diameter portion of the cap bolts are extended downwarlythrough reduced diameter portions of bores 28a and threaded into themounting plate 26. The cap bolts having shoulders (not shown) to abutagainst plate 26 and thereby form stops to limit the threading intoplate 26- Around the reduced diameter portion of each bolt 29 there isprovided a coil spring 30 which at the upper end abuts against the lowersurface of frame 28 and at the lower end abuts against mounting plate 26to resiliently urge the aligning frame upwardly against the shouldersformed by the enlarged diametric portions and reduced diametric portionsof bores 28a. The aligning frame in its uppermost position extends to anelevation substantially above the lower horizontal surfaces of tilepieces 16 on the tile board 10 when said board is on the constantternperature base 27; while the lower surface of frame 28 extends toslightly lower elevation than the top of base 27. The spacing of theframe 28 above the mounting plate in the datum position illustrated inFIGURE 2 is sufficient so that the aligning frame can be forceddownwardly against the action of the spring 30 to a position that theupper horizontal surfaces of the frame 28 is about even with or belowthe level of the general planar surface p0rtions of the board 10 (seeFIGURE 5). Also the diameters of the bore portions and the cap bolts aresuch that very close fits are formed whereby the frame 28 is retained ina horizontal condition to properly horizontally position the Iboard 10.

In order to pick up the individual tile pieces and positively retainthem in the same spaced relationship as when they are on the aligningplatform, there is provided a vacuum manifold assembly generallydesignated 36 (see FIGURES 3, 4 and 5) The manifold assembly includes amanifold plate 36 that in horizontal cross section is about the samesize and shape or larger than the tile mounting board. The manifoldplate is bolted or otherwise appropriately secured in the manifold body37 to be in depending relation thereto and in fluid sealing engagementtherewith (for example by a gasket), the manifold body in horizontalcross-sectional being substantially larger than the manifold plate. Themanifold body includes a manifold chamber 38 that opens to each of theplurality of bores 40 formed in the manifold plate (see FIGURE 4). Anupright boss 41 is secured to the top central portion of the manifoldbody 37 and may have a tiuid passageway 42 therein that opens into themanifold chamber through an appropriate aperture, formed in the manifoldbody. However as illustrated in FIGURE 4, mostly schematically, asolenoid operated vacuum control valve 44 is mounted on the manifold ina exible fluid line 43 which at one end opens through an aperture intothe manifold chamber 38. A vacuum gauge 47 is connected in line 43 to atall times indicate the pressure in the manifold chamber. A second exibleuid line 42 is at one end connected to a source of pressurized air 45and at the opposite end opens through an aperture to the manifoldchamber, there being provided a solenoid operated control valve 64connected in line 42 to control the application of pressurized air tosaid chamber.

Bolted to the underside of the manifold body in depending relationthereto and in abutting engagement with the manifold plate by bolts 50are a pair of parallel side rails 51 and parallel end rails 52; therebeing provided a metal spacer 53 intermediate each of the metal rails 5land 52, and the manifold body respectively. As may be noted from FIGURE3, the spacers 53 and the rails 51, 52 enclosed rectangular openings.The cross-sectional area of the opening enclosed by the spacers is of alarger cross-sectional area than that enclosed by rails. The rails 51,S2 respectively are mounted to have their inner vertical edgeshorizontally spaced from adjacent vertical faces of the outermost rowsof tile pieces and the tile mounting board 10 a distance approximatelyone half of that between adjacent pair of tile pieces on the tilemounting board when the manifold assembly 35 is lowered to pick up thetile pieces from the aligning platform 25. In order to insure theaforementioned spacing between the rails 51, 52 and the said verticalfaces of the tile pieces, a plurality of upright guide pins 33 aremounted on the mounting plate 26, the upper ends of the guide pins beingtapered. A plurality of spaced apertured guide lugs 58 are joined to theouter vertical edges of the manifold body such that the apertures ofsaid lugs are in the same spaced relationship as the guide pins on themounting plate. As the manifold body is lowered, the nontapered portionsof the guide pins are extended into the guide lug apertures to correctlyhorizontally position the manifold body relative to the aligningplatform, the relative positioning being such that as the rails 51, 52force the aligning frame 28 downwardly against the resilient action ofthe coil springs 30 and the inner vertical faces of said rails arespaced from the outer vertical surfaces of the tile pieces bysubstantially one half the width of a joint space (provided theoutermost rows of the tile pieces have previously arrayed to be inabutting engagement with the alignment frame in the FIGURE 2 position).This spacing between the rails 50, 51 and the outermost rows of tilepieces is indicated by dimension j in FIGURE 5.

Mounted on the manifold plate 36 in abutting engagement with the undersurface thereof by a plurality of manifold spools 55 is a pad 56 made ofresilient material. Preferably the pad is a solid sheet of silicone,however, a silicone sponge type pad can also be used. Additionally it isto be understood that other types of resilient material such as neoprenemay be used if coated with silicone tape or suitable material thatreadily releases the individual pieces of the tile and readily releasesthe subsequently used resinous material. Preferably the resilient pad isa resiliency of Air-Space Material Specification 3195 or if desired moreresilient material such as Air- Space Material Specification 190 -may beused. An advantage of using a silicone solid sheet pad or siliconesponge is that it does not adhere and will last longer than a siliconesponge. It is important that the resilient pad 56 will deflect in amanner set forth hereinafter and readily release from the materials usedin forming the finished tile panel. Also it preferably has to withstandcompression without taking a compression set within economic limits andhas to withstand high temperatures.

The resilient pad is of a size and shape to generally fill therectangular opening enclosed by the spacers 53, to overlay portions ofrails 51, 52; and of a height approximately equal to the distancebetween the upper surfaces of the rails 51, S2 and the bottom planarsurface of the manifold plate (see FIGURE 5). Also the resilient pad isprovided with a plurality of properly spaced perforations 56a, theperforations being spaced such that when the pad is positioned above thealigned tile pieces on the tile mounting board, each perforation 56aopens directly above a central horizontal portion of the upper surfaceof a tile piece 16. Each of the perforations is located to open to theadjacent rectangular bore 40 formed in the manifold plate. Provided ineach bore 40 intermediate opposite axial ends thereof is an annularretainer 60 that has a substantially smaller inside diameter than thecross-sectional dimensions of the bore. The annular retainer may be asteel pronged washer retained in a fixed axial position in the bore, orthe retainer 60 may be provided by making the manifold plate of aplurality of horizontal laminated layers of metal wherein the boresthrough the layers of metal provides a bore that in verticalcross-section is of the shape illustrated in FIGURE 8 other than thatthe retainer will be integrally formed With one of the intermediatelayers of metal.

A manifold spool 55 is mounted in each of the manifold plate bores andhas a reduced diameter portion 55a extended through the retaineraperture and the adjacent resilient pad perforation 56a. Integrallyformed with the reduced diameter portion 55a is a lower spool flange55b. Preferably the spool flange 55b is circular in horizontal crosssection and of a size and shape substantially larger than the padperforation and the retainer aperture, but of a substantially smallersize and shape than that of the manifold bore. Integrally joined to theopposite end of the reduced diameter portion 55a is an enlarged upper,rectangular spool flange 55C, the size and shape of spool flange 55Cbeing such that its outer perimetric surfaces form a close sliding fitwith the peripheral wall of the upper part of the manifold bore. Whenthe manifold plate is located a substantial distance above the tilepieces, the manifold spool in its lowermost position will have the upperflange 55a abutting against retainer `60` to preclude further loweringof the manifold spool relative to the manifold plate; while at the sametime, the upper horizontal surface of the lower flange 55b abuts againstthe lower surface of the resilient pad to hold the upper surface of theresilient pad in abutting relationship with the lower surfaces of themanifold plate. Each manifold spool includes a central vertical aperture55d that at its upper end opens through the lower surface of themanifold spool flange 5511 and at the opposite end opens through theupper surface of the manifold spool flange 55C. An example, eachaperture 55d may be 0.3 inch in diameter.

The manifod assembly is provided with a peripheral seal 62 that isattached to the manifold body to at its upper edge form a fluid sealingengagement with the lower surface perimetric edge portions of said body.The seal 62 is made of a closed cell sponge material of suflicientstrength to be self sustaining. The height of the sponge material in anon-compressed condition is such that the seal extends to an elevationto abut against the mounting plate 26 when the manifold assembly hasbeen lowered sufficiently that the spools just initially contact thetile pieces on the aligning platform. The inner surface of the seal 63is preferably horizontally spaced from the corresponding inner surfaceof the adjacent rail 51 or 52 by a dimension D. Preferably the dimensionD is suciently great so that the area of the entire perimetric channel(having a dimension D at right angles to the tile mounting board) isequal to or greater than twice the area .bounded by the outermost edgesof the outermost rows tile pieces on the tile mounting board (i.e. thatof the tile mounting board 10). A right angle perimetric metal flange 63has a horizontal leg secured to the manifold plate and a vertical leg inabutting relation with the seal 62. The vertical leg is of a verticaldimension that is slightly less than the distance between the lower edgeof the rails 51 and 52 respectively to the under surface of the manifoldbody.

The inner vertical surfaces of the vertical flange leg and seal member62 respectively together with adjacent vertical surfaces of the spacers53, rails 51 and 52 respectively, and the horizontal surface of themanifold body intermediate the vertical leg of member 63 and spacers 53,in vertical cross-section form a generally U-shaped perimetric channel65 that extends completely around the tile pieces and is locatedoutwardly therefrom. The purpose of providing this channel will becomemore apparent hereinafter.

The manifold assembly is provided with a bore that at one end opens intothe interior of the channel 65 and at the other end opens to one end ofa flexible fluid line 67, the opposite end of line 67 being connected tovacuum source 46. A solenoid operated control valve 69 is connected inline 67 to control the application of vacuum to said channel. A vacuumgauge 68 is connected in line 67 to all times indicate the pressuretherein. Another flexible fluid line 71 at one end opens to the sourceof pressurized air 45 and at the opposite end to a bore 73 that opens tochannel `65, there being provided a solenoid operated control valve 72in line 71 to control the application of pressurized air to channel `65.

There is also provided a heat transfer support member 75 having a planartop surface that readily releases from the subsequently applied resinousmixture. Secured to the heat transfer member are a plurality of upwardlyextending guide pins 76 that are located in the same horizontal spacedrelationship as guide pins 33 of the aligning platform.

The support members 75 has a plurality of tubular passageways 77 locatedbeneath the upper horizontal surface thereof for selectively heating andcooling the top surface of said support member. Thus when it is desiredto apply heat through support member 75, steam is passed through saidpassageways; while when it is to be cooled, cool water is passed throughsaid passageways.

In order to apply resin to the upper surface of the support member inthe desired pattern, there is provided a pattern board 80 having aplurality of apertured guide lugs 81 to cooperate with the guide pins 76to properly horizontally position the pattern 'board on the supportmember 75. The pattern fboard has a cut out 82 which advantageously maybe shaped as illustrated in FIG-URE 7. The size and shape of the cut out81 is such that when the board S is positioned on the support member thecut out portion will retain a predetermined quantity of uncured resinousmaterial 84 that is to be used in forming the finished tile panel.

The structure of the rst embodiment of the invention having beendescribed, the method of using such structure to form a preformed tilepanel will now be set forth. Initially the tile mounting board 10 ispositioned on the vibratory base 12 with the grids facing up. Next aweighted quantity of tile pieces are dumped onto the board within theconfines of the frame 19. As the board 10 is vibrated in a horizontaldirection (both longitudinal and transverse vibrations in horizontalplane) the majority of tile pieces are arrayed to lay at against theplanar surface portions of the board such as illustrated in FIGURE 1.The remaining portion, (roughly in the neighborhood of 3%) are rapidlywiped into position by hand. After all the tile pieces have been arrayedon the tile mounting board, the board is removed from the base 12 (forexample by a plunger extending upwardly through the base, not shown, orby first removing frame 19); and then the board with arrayed tile piecesthereon are seated upon the base 27 of the aligning platform 25. At thistime the coil springs 30 retain the aligning frame 28 such that theupper surface of said frame is at a higher elevation than the lowerportions of the tile pieces. Due to slight variations in the dimensionof the tiles (within the desired tolerances) the outer vertical surfacesof some of the tile pieces in the outermost rows of tile pieces will bespaced from the inner surfaces of adjacent frame member of frame 28.Accordingly with rapid sweeping motions of the operators hand all thetile pieces in the outermost rows are swept to abut against the adjacentvertical surfaces of the aligning frame. In this connection it is to benoted that both base 12 and base 27 are retained at the same constanttemperature (by conventional mechanism-not shown) to substantiallyeliminate any undesired alignment of tile pieces due to temperaturevariations of the mounting board 10.

After the tile pieces have been aligned through the use of alignmentplatform, the manifold assembly is lowered through suitable conventionalmechanism (not shown), for example, a pulley assembly that at one end isconnected to suitable supporting structure and at the other end to theboss 41 of the manifold assembly. Due to the provision of the guide pins33 and the lugs 58 the manifold assembly will be properly horizontallypositioned relative to the tile pieces on the mounting platform suchthat each of the manifold spools 55 will be centrally located in apredetermined position relative to the upper surface of the respectivetile piece that it abuttingly engages. At about the time the manifoldassembly has been lowered so that the manifold spools initially Contactthe upper surfaces of the tile pieces, seal 62 forms a uid sealingengagement with the mounting plate 26. Now valve 69 is turned so thatvacuum source 46 is connected to the channel 65, valve 44 being closed.Initial application of vacuum through valve 69 to the channel 65 resultsin the air pressure acting on the upper surface of the manifold assemblyforcing said assembly to move in a downward direction and thereby theseal 62 being compressed, The vacuum applied to channel 65 is. alsoapplied to manifold chamber 38 through the slotted portions 86 of therail 51, 52 (see slots in FIGURE 8), the joint spaces between the tilepieces, thence over the top surfaces 0f the tile pieces and through theapertures 55d of the manifold spools to the manifold chamber. Thus thegauge pressures indicated by gauges 47 and 68 during the initialwithdrawal of air from charnel 65 are approximately the same. Howeverwhen the vacuum has drawn the manifold assembly downwardly suicientlyrelative to the mounting plate 26, the tile pieces force the manifoldspools upwardly to space the upper flanges 55C above the retainers 60;and subsequently bring the tile pieces into fluid sealing engagementwith the resilient pad 56 (for example at about minus 5-6 in. of Hg).

At the time all the top tile pieces are in uid sealing engagement withthe resilient pad, the pressure in the manifold chamber no longer dropsand this is reflected by the gauge pressure of gauge 68 continuing todrop while the gauge pressure of gauge 47 stays substantially the same.At this time the manifold assembly, the aligning platform 25, and thetile pieces are in relative positions similar to that illustrated inFIGURE 5; the resilient pad being somewhat extruded down into the jointspaces between the tile pieces and the rails 51, 52 having forced thealignment frame downwardly so that the upper surface is Substantiallylevel with the upper planar surface portions of the tile mounting board(FIGURE 4).

Now the valve 69 is operated so that there is no duid communicationthrough line 67 to the ambient atmosphere or between source 46 andchannel 65; the valve 44 is operated so that line 43 place the vacuumsource in fluid communication with chamber 38. Additional air iswithdrawn from the manifold chamber, plate 36 is lowered and the seal 62is further compressed. This results in the resilient pad portions beingdeflected upwardly into the manifold plate bores 40 from the manifoldspools (and pad material adjacent the spool bores) since the tile piecesand manifold spools remain stationery and plate 36 moves downwardly tocompress the pad more than it had been previously compressed. After thepressure has suiciently dropped in the manifold chamber to accomplishthe foregoing (for example to 20 in. of mercury), then valve 72 isoperated to permit the application of pressurized air from source 45through line 71 to channel 65. The application of pressurized air tochannel 65 results in the manifold assembly with the tile pieces thereonbeing elevated since channel 65 is returned to atmospheric pressure.Then valve 72 is again operated to a closed condition.

At about the same time the tile pieces are being aixed to the manifoldassembly as described above, the pattern board is arrayed on the uppersurface of the heat transfer support member with the pins 7-6 extendedthrough the guide lugs 81. Now a predetermined quantity of uncuredresinous lmixture is deposited in the cut out 82. The resin mixture ispreferably a polyether polyurethene type resin although other typeresins can be used. Further the resin mixture is of a viscosity so thatit does not readily flow upon removal of the pattern board 80 from theheat transfer support member.

After the pattern board has been removed, the manifold assembly 35'V ismechanically lowered onto the support member 75 such that the guide lugs58 engage the guide pins 76 to properly align the manifold assembly withreference to the heat transfer support member. After the seal 62 hasinitially engaged the support member, the manifold assembly is no longermechanically supported; however, the lands 51a of rails 51, 52 areslightly spaced above the top surface of support member 75. At this timevacuum is applied through line 67 to channel 65 by operating valve 69 toan open condition, the tile pieces at this time either abutting againstthe resin mixture 84 or just about to abut against said resin mixture.This application of vacuum withdraws air from the channel 65 and due tothe spacing of the rails 51, 52 and the slots 86 provided thereinbetween lands 51a, also applied vacuum in the voids between the tilepieces and the voids between the under surfaces of the tile pieces andthe support member 75. This application of vacuum to the channel 65draws the manifold assembly downwardly and compresses the seal 62; andthen draw the resin mixture toward the rails slots 86. At about, forexample, minus in. of mercury to channel 65, the manifold assembly hasdrawn downwardly so that the seal 62 has been sufciently compressed thatthe lands 51 abut against the support member 75 to prevent furtherdownward movement of the manifold assembly relative to the supportmember. Since at least some of the tile pieces bear against the resinmixture, the aforementioned downward movement of the manifold assemblyis faster than that of said tile pieces which results in more resilientmaterial being forced into the joint spaces adjacent said tile pieces. j

Air is withdrawn from the voids between the resilient pad and thesupport member much more rapidly than the resin mixture can flow towardthe lands; and accordingly the vacuum between the voids and the jointspaces between the tile pieces draws the resin mixture upwardly to tillthe voids in the joint spaces between the tile pieces. As the resinmixture ilows into each slot 86, the vacuum from the channel beingapplied to the resin mixture through each such slot is applied to a muchmore limited area of the resin mixture, the size of each slot being suchto retard the flow of resin mixture therethrough and thereby limit theflashing that exists under rails 51, 52. As a result of the applicationof vacuum to the resin mixture, the resin mixture rapidly spreads tofill all the voids between the rails 50, 51 and the resilient pad andsupport member.

To be mentioned is that the pressure diiferential between the channel 65and the manifold chamber is suiciently great so that the tile pieceswill be drawn upwardly toward the manifold chamber with suficientlygreat force to deect a sucient amount of pad material into the jointSpaces between adjacent tile pieces. This results in the resin mixturebeing concavely curved to form continuations of finished surfaces of thetile pieces to produce a nished appearing grouted surfaces regardless ofwhether or not the tile pieces have beveled edge adjacent the nishedsurfaces. Also the above -mentioned force is suicient to precludeseepage of resinous material between the tile pieces and the resin padinto contact with the finished surfaces of the tile pieces even throughthe vacuum is being applied to channel 65. Thus the maximum vacuumapplied to channel 65 during this step is about minus 12 or 13 in. ofHg.

After the sufficient quantity of air has been pulled out of the channeland the resin has flowed suiciently to close all the vents 86, vacuum nolonger will be applied from the channel to the joint spaces between tilepieces other than that which has been trapped. The vacuum trapped invarious pockets formed due to the non uniform ow of the resinousmaterial, causes the resinous material to fill said pocket and relievestresses where there has been a build up of excess material.

As the resin mixture is pulled upwardly relative to the support memberinto the joint spaces, it relieves the compressed forces exerted thereonby the tile pieces. As a result the extra pad material that was forcedin an upward direction (overly compressed) now returns the tile piecesto a position more closely adjacent the support member surface. Thus atthe time the resinous mixture has spread to ow into all, orsubstantially all of the vents, the resinous mixture isolates theindividual tile pieces from the application of the vacuum in the channel65. Further at the time the vacuum in the channel is lowered to about 5"(by way of illustration and not a limitation), heating uid was passedthrough the support member passageway 77. The initial heating of theresinous mixture causes it to ow more rapidly, but it is rapidly curedthereafter. These factors contribute to the resinous mixture completelylling the voids -between the tile pieces while at the same time theresilient pad moves the tile pieces to the desired height above thesupport plate, for example, .l0-.l5 inch.

To be mentioned, it is advantageous to use a manifold plate having lowerrectangular bore portion 40a (FIG- URE S) rather than cylindrical shapedbore portions since the distribution of force acting to cause deflectionof the resilient pad into the joint spaces is more evenly distributedaround the tile piece than if a cylindrical flange was used. That is inusing a cylindrical bore portion adjacent the pad, a finished surface ofthe joint spaces may be very slightly uneven since the distance from acorner edge of a tile piece to the projection of the cylindrical boreportion is less than the distance from the mid point of the tile pieceto the central axis of said cylindrical bore portion. Thus the manifoldlplate 36 advantageously includes a lower member 36a having thegenerally rectangular bore portions 40a formed therein that forms partof bores 40, member 36a being in fluid sealing engagement with themember `of the plate 36 to which it is attached.

After the resin mixture has sufficiently cured, valves 44, 69 areoperated to a closed condition and air under a pressure applied throughvalves 64, 72 to return the manifold chamber and channel 65 toatmospheric pressure. The tile panel is removed and the flashing thatextended into vents 86 is trimmed off. As a result there is provided thefinished tile panel 90 which is partly illustrated in FIG. 10. The panel90 includes the plurality of spaced tile pieces 16 and the hardened,cured resinous mixture mounting said tile pieces which comprises abacking layer 91 have a substantially planar back surface, a perimetricborder 92 that surrounds the outermost rows of tile pieces of the panel,and joints 93 that ll the prior joint spaces between the tile pieces.The backing 91, border 92 and joints 93 are integrally joined, the widthW of the border being substantially one half of the correspondingdimension of a joint. Further the finished surfaces 94 of the joints areconcavely curved, the appearance of the top surface of panel 90 beingthe same as that of panel 148 illustrated in FIGURE 15. In thisconnection note that rails 51, 52 have a recess 51d so that theperimetric border will have one half of a concaved curved surface.

Due to the provision of borders 92, two tile panels 90 can be placed inedge abutting relationship and from a very short distance it is notobvious where one panel ends and the other begins. The panels can beeasily nailed to a supporting surface by driving nails through thejoints or through the use of a suitable adhesive applied to the backsurface of the panel adhered to the supporting surface.

Referring to FIGURES 1l-14 there is in part illustrated a secondembodiment of the invention which includes a gridded tile mounting boardhaving a generally planar tile mounting board 110. A plurality ofparallel longitudinally extending grids and parallel transverselyextending grids 113 are integrally formed with the upper surface portionof the tile mounting board to demark an area of a size and shape toretain the individual tile pieces 116 in the ultimate desired horizontalspaced relationship (transversely and longitudinally) of the preformedtile panel.

After the tile pieces 116 have been properly positioned on the tilemounting board, then the vacuum manifold assembly, generally designated115, is lowered onto the tile mounting board to pick up the tile pieceswhile retaining them in the spaced relationship in which they have beenpositioned on the board 110. The manifold assembly includes a manifoldplate 118 that in horizontal cross section is about or greater thantwice the area of the tile mounting board. Bolted to the underside ofthe manifold plate by bolts 119 in depending relation are a pair ofparallel side rails and a pair of parallel end rails 120;

there being provided a spacer 122 intermediate each of the rails and themanifold plate respectively. The spacers 122 and the rails 120 enclosegenerally rectangular openings similar to that disclosed relative thefirst embodiment. The rails 120 respectievly are mounted to have theirinner vertical edges horizontally spaced from the adjacent verticalfaces of the outermost rows of tile pieces a distance approximatelyone-half of that between the adjacent pair of tile pieces on the tilemounting board.

Also mounted on the manifold plate 118 in abutting engagement with theundersurface thereof by a plurality of manifold spools 125 is a pad 117made of resilient material, the material preferably being the same asthat described relative pad 56, and of a size similar to that describedrelative said first embodiment.

The resilient pad has a plurality of perforations 117a formed therein;the perforations being spaced similarly to that disclosed relativeperforations 56a. Each of the perforations 117:1 is located to open tothe reduced diameter bore portion 118d of the adjacent bore formed inthe manifold plate, each bore including an enlarged di ametric portion118e` that at its lower end opens to the lower portion 118:1 to form ashoulder 118e therewith and also opens through the upper surface of themanifold plate.

A manifold spool 125 is mounted in each of the manifold plate bores andhas a reduced diameter portion 12511 extended through the adjacent boreportion 118d and the adjacent resilient pad perforation 117a. Integrallyformed with the reduced diameter portion 125a is a lower cylindricalspool flange 125b that has a substantially larger outside diameter thanthe diameter of the pad perforation but a substantially smaller diameterthan the diameter of the bore portion 118d. integrally joined to theopposite end of the reduced diameter portion 125:1 is an enlarged uppercylindrical flange 125C, the outer diameter of the flange 125e` Ibeingsuch that the outer peripheral portion thereof forms a close sliding fitwith the peripheral wall of the manifold plate wall bore portion 118C.Accordingly, when the manifold spool is in its lowermost position, theupper flange 125s` rests on the shoulder 118e to preclude furtherlowering of the manifold spool relative to the manifold plate; while atthe same time, the upper horizontal surface of the lower flange 25babuts against the lower surface of the resilient pad to hold the uppersurface of the resilient pad in abutting relationship with the lowersurface of the manifold plate. Each manifold spool includes a centralvertical aperture 125d that at its lower end opens through the lowersurface of the spool flange 125b and at the opposite end opensv throughthe uper surface of the spool flange 125C. As an example, the aperture125d may be 0.3 inch in diameter.

The manifold plate 118 is bolted or otherwise appropriately secured tothe manifold body 127 to be in depending relationship thereto and influid sealing engagement therewith. The manifold body includes amanifold chamber 128 that opens to each of the manifold plate boreportions 18e (see FIGURE 12). An upright boss 130 is secured to thecentral top portion of the manifold body 127, the boss 130 having afluid passageway 131 therein that opens into the manifold chamberthrough an appropriate aperture formed in the manifold body. Theopposite end of the fluid passageway 131 is fluidly connected to avacuum source 121.

After the tile pieces have been positioned on the tile board, themanifold assembly 115 is mechanically low. ered sufliciently to bringthe lower surface of each spool flange 125b into abutting engagementwith the upper central surface of a tile piece on the tile mountingboard. At this time the lower horizontal surface of the resilient pad isstill in a planar condition. Also the peripheral depending flanges118;!c of the manifold plate together with the seal member 133 that isattached to the lower horizontal surface of said depending flanges arestill vertically spaced above the upper surface of the tile mountingboard by a distance of approximately equal to the depth of the spoolflange b. The inner vertical surfaces of the depending flanges and theseal member, together with the adjacent vertical surfaces of the spacers122, rails 120, and the horizontal surface lof the manifold plateintermediate the depending Aflanges and the spacers 122, in verticalcross section form a generally U-shaped channel 135 that extendscompletely around the tile pieces and is located outwardly therefrom.

The manifold assembly is further mechanically lowered until theperipheral seal 133 abuts against the tile mounting board. This furtherlowering of the manifold assembly results in the spools 125 being movedupwardly due to their butting against the tile pieces (from FIGURE 11position to FIGURE 12 position). This upward movement of the spoolsthrough the spool flanges 125b, results in annular portions of theresilient pad adjacent said spool flange 125b being deflected upwardlyinto bore 118, and also the upper spool flanges 125C being lifted offthe shoulders 118C. After the peripheral seal 133 is moved into abuttingengagement with the tile mounting board and the spools have moved in theaforementioned manner, vacuum is applied through the boss to themanifold chamber 128 and thereby to the manifold bore portions 118c andthrough spool apertures 125d to the central top portion of the tilepieces.

The initial application of vacuum will, due to leakage around spoolflanges 125 and the adjacent tile pieces, result in the withdrawal ofair from the space bounded by seal 133, the manifold plate and thealignment platform to thereby draw the manifold body downwardly andcompress seal 133. This downward movement of the manifold body willcause the initial compression of the resilient pad to deform it suchthat it will abut against the tile pieces and form an angular pocket117i around flange 125b (see FIGURE 13 where this pocket is of reducedsize due to still further compression of the pad). Since the spools makethe initial contact with the tile pieces, the spools reduce the abrasionof the pad from what would occur if no spools were provided (this beingthe case for all embodiments of the invention where manifold spools areprovided).

Due to the resilient pad abutting against the tile piece there is formeda fluid seal, which effectively makes the spool flange a part of the padface after the spools move relatively upwardly as mentioned below. Thenthe effective area of application of vacuum to a tile piece is the sameas the downwardly projected horizontal area of the portion `of bore 40just above the pad.

Due to formation of the aforementioned seals and the piston effect ofthe spools, the spools are drawn by the vacuum to move further in anupward direction, this relieving the pressure exerted by the tile pieceson the mounting board and thereby the vacuum in the perimetric channeldrawing the manifold assembly downwardly to compensate for the relief ofpressure so that the tile pieces remain in contact with the tilemounting board. At the same time this movement causes the resilientmaterial surrounding the tile pieces to be deformed into the voidsbetween adjacent tile pieces similar to that illustrated in FIGURE 13.That is the application of vacuum in causing further relative upwardmovement of the spools and tile pieces further compresses the resilientpad to cause convexly curved deflections of the material 117b into thejoint spaces between the tile pieces. A vacuum of 20 inches of mercuryapplied through boss 130 to chamber 128 is suitable for compressing thepad 117 of suitable durometer to cause the proper deflection of saidpad. At this time the manifold assembly, together with the ti-le piecesaffixed thereto through the application of vacuum to the manifoldchamber, is moved away from the tile board (the vacuum in the perimetricchannel being released in a suitable manner such as described inconnection with other embodiments); and if the tile pieces 13 have notbeen previously treated with a primer, the tile pieces may be dippedinto a suitable container of primer to condition the tile surfaces sothat a subsequently applied resinous material will firmly adherethereto.

Now the manifold assembly together with the tile pieces aliixed theretois lowered onto the generally planar heat transfer support member 140that has longitudinal and transverse grids 141 of the same size, shapeand configuration as the grids 113 of the tile mounting board. When themanifold assembly is lowered unto the support member 140, the grids 141are in the same vertical relationship to the tile pieces on saidassembly as that of the tile pieces relative to the grids 113 of thetile mounting board.

The support member 140 has a plurality of tubular passages 145 locatedbeneath the upper horizontal surface thereof for selectively applyingheat and cooling the top surfaces of said support member. At the timethe manifold is being lowered the support member is in a cooledcondition.

Prior to lowering the tile pieces to the proper position relative thesupport member 140 to form a tile panel, an uncured resin mixture in anappropriate quantity is placed on the top surface of the support member140 which is coated to readily release from the resin mixture. Forexample, the resin mixture may be placed on the support member 140 `overthe gridded surface through the use of a pattern board similar to thatdescribed relative FIGURES 6 and 7.

The manifold assembly is lowered to bring the seal member 133 intosealing engagement with the support member 140 and then a vacuum isapplied through a connection 143 that at one end opens through theaperture 146 into the peripheral channel 135 and at the opposite end isfluidly connected through line 142 to the vacuum source 144. Thisapplication of vacuum (for example, 13 to 14 in. of mercury) withdrawsair from the channel 135; and due to the spacing of the rails 120 abovethe support member 140 (the bottom surfaces of the rails being planar,i.e. no lands such as 51a), also applied vacuum in the voids between thetile pieces and the voids between the under surfaces of the tile piecesand the support member 141 (and resin mixture), if any. This applicationof vacuum through the channel 135 draws the manifold assembly downwardlyand compresses seal 133.

Now the uncured resin mixture is heated due to passage of, for example,steam through passageway 145. Due to the vacuum applied through line 142drawing the manifold assembly with tile pieces downwardly against theresin mixture, the resin mixture completely lls the voids between thetile pieces and said pieces and support member 140. There advantageouslybe provided spaced stops on support members 140 to abut against rails120 to limit the downward movement of assembly 115.

That is the resin mixture fills the voids (joint spaces) between thetile pieces, and at the location of contact with the pad 117 provides afinished surface. This results since the application of vacuum throughmanifold spools draws the tile pieces toward the manifold plate 121 withsuf-iicient force to cause portions 117a of the resilient material 117to be extrued into the joint spaces between the tile pieces a sufhcientamount so that the resin mixture will be contoured adjacent the finishedsurfaces of the tile pieces to produce a finished appearing groutedsurfaces regardless whether or not the tile pieces have beveled edgesadjacent the finished surfaces. Also the above mentioned force issufficient to preclude seepage of the resinous material between the tilepieces and the resilient pad into contact with the finished surfaces ofthe tile pieces even though a vacuum is also being applied throughchannel 135. The backing has grid lines (indentations extendingtransversely and longitudinally) on the back surface thereof as a resultof the cross intersecting grids 141. Thus the resinous material lls thevoids between the unfinished surfaces of the tile pieces and the bottomsurface of the support 140 to provide a backing having a griddedexterior surface that is integrally joined to the resinous material inthe joint spaces between the tile pieces.

It is to be noted that the vacuum applied between the voids of the tilepieces draws the resin mixture therein faster than the resin mixture caniiow outwardly beneath the rails 120. Further the vacuum applied throughboss 130 is suiciently greater than that applied through line 142 sothat the tile pieces are held against the pad 117 similar to thatillustrated in FIGURE 13 and described above. The resin is substantiallycured before the manifold assembly is raised from the support member140.

After the resin mixture is substantially cured, the application ofvacuum through port 143 is discontinued and then either the manifoldassembly raised and then the preformed tile panel removed therefrom; orelse the vacuum being applied through the chamber 127 discontinued priorto the raising of the vacuum manifold assembly. In either event afterthe preformed top panel has been removed from either the manifold member140 or assembly respectively, it is trimmed to remove the excessmaterial around the. peripheral border including that which flowedbetween the rails and the tile pieces to provide the finished panel 148of FIGURES 15 and 16. The panel 148 includes the tile pieces 116 boundedtogether through cured resin material backing layer 150 which isintegrally formed with the joint material 149. Since during the formingof the panel, pad portions 117b extended into the joint spaces, thefinished surface of the panel 148 is concavely curved at 14911 toprovide a finished grouted appearing jointly.

Where a plurality of panels are going to be used in edge abuttingrelationship than only the excess material that seeped under the siderails 120 is trimmed off. This way each panel at each edge has about onehalf of the joint material between adjacent rows of tile piece of twoadjacent panels as indicated by 149b.

Although the tile pieces illustrated have non-beveled edges, it is to beunderstood that where tile pieces having beveled edges are used, thesurfaces 149a form a continuation of finished beveled surfaces ratherthan the resin material covering the beveled edges on the finished sideof the tile pieces. That is during the time beveled edge tile pieces areaixed to the manifold assembly, pad material adjacent that of 117b wouldbe deformed to fill the cut out beveled portions of the tile pieces thatare adjacent to pad 117.

To be noted, with reference to FIGURE 14, is that when the tile piecesare in their lowermost position, the generally planar bottom surfacesare vertically spaced above the planar ungridded portions of the supportabout the same distance as the height of the triangular shaped grid 141,the height of the grids being a dimension X. The aforementioned spacingof the unfinished surfaces of the tile pieces from the ungriddedportions of the support 140 is of a dimension to give a desiredthickness of backing to the resulting tile panel, it being noted thatthe grids apexes are adjacent and between the joint spaces of the tilepieces. Due to the provision of grids 141, the finished tile panel hastransversely and longitudinally extending notched out portions 151 and152 respectively in the backing 150. The purpose of providing the gridson member 140 is to break the stress lines that otherwise would extendacross the backing and would cause the subsequently formed tile panel tocurve or warp; especially, if it were attempted to provide a fast cure.

Advantages of forming tile panels 148 as described above are that iteliminates providing a backing such as fiber glass backing and still atthe same time produces a tile panel having enouugh tensile strength tosupport its own weight and enough elongation to flex. The grid lines151, 152 formed in the panel backing 150' permit making hard joints andat the same time permits fast curing without the setting up ofundesirable stresses. Additionally through the provision of grid linesin the back surface portions of the tile panels, the amount of resinrequired to form the tile panel is decreased. Further by using anappropriate resin, a sponge of the nature set forth above, and providinggrid lines in the tile backing, the thus formed tile panels canwithstand temperatures such as for example 450 F. and still not get toobrittle at temperatures of F. below. Accordingly there is very littlelikelihood of the tile pieces cracking at cold temperatures or thepanels losing their strength in the event they are subjected torelativedly high temperatures. Additionally through the provision of thepanel grid lines, the iinished panel will deform suficiently to conformto somewhat Warped surfaces, provided the degree of warping is not toogreat. Usually the process of FIGURES 11-14 is used where it is desiredto luse a substantiail thicker backing layer than which is producedusing the process of FIGURES 1-10.

As a less preferable way than that described relative FIGURES 11-14, thetile panels may be made by using a gridded tile mounting board having anupright perimetric flange that is spaced a small distance from theoutermost grids. In place of the manifold assembly there is provided amanifold body of a size to abut on said perimetric flange and a manifoldplate secured to the manifold body to provide a manifold chamber, saidplate 'being of a larger cross sectional area than the gridded are ofthe tile mounting board but a slightly small area than that enclosed bysaid anges. There is provided a resilient pad having apertures spacedsimilar to that of pad 117 but of about the same diametric spoolapertures 125d the pad apertures being spaced to open through themanifonld plate apertures to the manifold chamber. The diameters of thepad apertures and the manifold apertures are about equal. Advantageousthe combined thickness of a tile piece, the resilient pad and manifoldplate is slightly less than the height of the perimetric flange abovethe planar surface portions of the tile mounting board.

In using the thus modified manifold assembly, the tile pieces arepositioned on the tile mounting board; and if the resilient pad is notattached to the manifold plate, it is first properly positioned over thetile pieces and then the manifonld assembly lowered to register themanifold plate and pad apertures. Then a vacuum is applied to pick upthe tile pieces and cause the pad to deform into the joint spaces asdescribed heretofore.

The thus picked up tile pieces are then lowered into a resin pan havinga gridded bottom and a perimetric flange to form a uid seal with themanifold body; and at the same time, space the bottom surfaces of thetile pieces above the pan bottom such as illustrated with reference tothe support member of FIGURE 14, when a vacuum is applied through a portin the pad perimetric ange that is in fluid communication with the jointspace voids. A liquid resin mixture may be pumped or allowed to flowthrough a supply port to form the joint space and backing material(similar to that illustrated for the resin of FIGURE 14) after a vacuumhas been applied through said vacuum port. Advantageously the pan may beprovided with an annular shoulder having a horizontal surfaceunderlaying but slightly vertically spaced from the lower surfaces ofthe pad that extend horizontally outwardly of the tile pieces. Thevacuum port and resin supply port open into this space on oppositesides, the annular shoulder vertical surface being spaced from thevertical surfaces of the outer rows of tile pieces as disclosed relativeto rails 120. Also to be indicated is that the resin pan may be heatedand cooled by, for example, the provision of tubular passageways throughthe pan. After curing and trimming, the finished tile panel using themodified apparatus would be the same as described heretofore relativeFIGURES l5 and 16.

It is also contemplated that the tile panels may be automatically formedas will be described hereinafter. For

example, mechanism for forming such tile pieces includes a continuousconveyor generally designated that includes a pair of chains extendedover axial spaced sprockets 162 on an idler shaft 163 at one end and asecond pair of axial spaced sprockets on the drive shaft 164 at theopposite end (see FIGURES 17-20). Each of the aforementioned chainsincludes a plurality of mounting links 166 and connector links 167 whichare pivotally connected at 168 with a link 167 between each pair oflinks 166. Between transversely corresponding pairs of links 166 of thechains and mounted on offsets 166a of a pair of links 166 is atransversely elongated block 169 having an upwardly extending flange169a at the rear- Ward edge thereof, the direction of travel of theupper run of the conveyor 160 being indicated by arrow 170. Thelongitudinal length of each block is such that each adjacent pair ofblocks is longitudinally spaced by links 166 in order to permit thembeing carried around the sprockets 162.

Each of the flanges 169a is provided with a plurality of grooves 169Cthrough which longitudinally extending wires 171 are passed. As may benoted from FIGURE 20, the height of a flange 169a is less than theheight of a tile piece 172 positioned on the horizontal ieg 169d of theblock. Advantageously a vibrated support 175 is attached to each of theone ends of the wires tovibrate the wires to transversely space the tilepieces that are placed on the blocks, the opposite ends of the wiresbeing attached to a ltransverse support member 176. The aforementionedspacing of the tile pieces is such to conform to the spacing of the tilepieces in the subsequently finished panel.

The second conveyor or chute 179 is mounted on structure (not shown) tohave the forward edge thereof extend over and adjacent the rearward endof the upper run of the conveyor 160, the bottom edge of the chute 179being slightly vertically spaced above the top edge of the upper runblock flanges A16911. The chute advantageously may be provided withlongitudinally extending ribs 180 for properly or at least partiallytransversely spacing the individual tile pieces 172 (which have bentreated -with primer before being placed on the chute) before they aredropped onto a block 169 passing beneath the forward edge of the chute.Advantageously the chute also may be inclined at an angle such that aslight pushing force is required to push the forwardmost tile pieces onthe chute to drop onto the respective block. As may be noted from FIG-URE 20, the flanges of adjacent pairs of blocks are longitudinallyspaced a slightly greater distance than the longitudinal length of thetile piece. Accordingly the block anges properly longitudinally spacethe tile pieces.

In advance of the froward end of the chute 179, there is mounted abristle brush 183 rotating in the direction of arrow 84 to brush thetile pieces `against the vertical surface of the respective flange 169aand to clean the horizontal tile surfaces of the tile -pieces on theconveyor 160 as the upper run there is moved ina forward direction. Thiseven more longitudinally aligns the tile pieces to properlylongitudinally space them.

In order to form tile panels after the tile pieces are positioned on andcarried by the continuous conveyor, there is provided a manifoldassembly, generally designated 190, which is of a somewhat modifiedconstruction from that of manifold assembly 115. The assembly 190includes a manifold body 127 having a manifold chamber 128, a manifoldplate 190d having spool apertures for mounting spools 12S, `a resilientpad 117 mounted by spools 125 on the manifold body and spaces 122.However there is not provided rails 120; the manifold plate dependingange 190e together with the peripheral seal extended to about the sameelevation as the bottom surface of spacers 122 providing a perimetricchannel 190]t into which the vacuum connection 191 opens.

The manifold assembly 190 has an upwardly extending boss 194 that at itsupper end is connected to the radially extending arrn 195, the oppositeend of arm 195 being connected to a rotary portion of a central post196. The post includes a stationary portion, the stationary and rotaryportions including cooperating structure 196a to: provide a valvingaction las described hereinafter. The boss 194, radial arm l195 and therotary post portion have a uid passageway 197 for placing the manifoldchamer of manifold body in fluid communication with said valvingstructure 196:1 for controlling the application of vacuum from thevacuum source to the manifold chamber in the desired timed relationship.The valving structure 196a is diagrammatic illustrated in FIGURE 18 asspaced from the post but actually would be located within the post.Since the structure for controlling the application of vacuum does notform a part of this invention, it will not be described. Additionallyconnected to the post 196 is suitable indexing mechanism designated 198.The indexing mechanism is synchronized with the movement of the conveyor160 such that when the conveyor 160 is stopped, the manifold -190 islowered to pick up a plurality of tile pieces (solid line position ofFIGURE 19, phantom position 190a of FIGURE 18). 'Ihen a vacuum isapplied through valving 196a and passageway 197 to the manifold chamberto pick up the tile pieces 172 and then the manifold assembly elevated.Next the conveyor 160 is actuated and the indexer swings the post y196in the direction of arrow 207 to position the manifold assembly abovethe support member 200 (solid line FIGURE 18 position). The manifoldassembly is then lowered into sealing engagement with support member 200(if necessary, suitable guides being provided along side the supportmembers).

The support member is somewhat modified from that of support member 140,support member 200 including a perimetric ange 200a to abut against thedepending flange 190e of the manifold plate and form a fluid sealtherewith. Flanges 190e, 200g are of heights to space the bottom surfaceof the manifold plate, through which spools 125 extend, substantiallythe same distance from the top gridded surface of support member 200 asindicated for the corresponding structure of FIGURE 14. The supportmember perimetric shoulder 2001; has inner vertical surfacescorrespondingly located as inner Ivertical surfaces of rails 120 and atop surface that is vertical spaced from the spacers 122 of assembly'190 an amount corresponding to the spacing of the bottom rails 120 fromthe non gridded surface of support mem-ber 140 as shown in FIGURE 14.

The shoulder 200b has a port 201 that opens through the inner verticalsurface of the shoulder 20Gb'. The port 201 is fluidly connected throughcontrol meter valving 202 which in turn is connected to the liquid resinsupply 203. After a vacuum has lbeen applied to channel 1901t throughvacuum connection 191, the valve 202 opens to meter beneath the manifoldassembly 190 (pump onto the support member) an appropriate amount ofresin mixture from the supply 203 which then is turned offautomatically. The resin mixture lls the voilds to -provide the backingand joint material similar to that indicated with reference to FIGURE14. Now the application of vacuum through connection 191 is discontinuedand the pressure in chamber 190f returned to atmosphere.

With reference to the application of vacuum through connection 191, itis fluidly connected to the valving 196a through fluid line 204 whichextends along arm 195 and down through a separate iluid passageway inthe rotary post portion to valving 19651. The indexer discontinues thevacuum through line 204 and after the resin mixture is substantiallycured, elevates the manifold assembly and then swings it above conveyor204 (phantom position 190b of FIGURE 18). At this time the vacuum in themanifold chamber is discontinued, said chamber returned to atmosphericpressure, and the tile panel released onto conveyor 204a to besubsequently trimmed and stored. Then the manifold assembly is againswung to yposition 190a of FIG-URE 18 and lowered to repeat the cycle.

Although only one manifold assembly and associate structure forcontrolling the movement of and operation of said assembly has beendescribed and illustrated, it is to be understood a number oflongitudinally spaced posts, manifold assemblies, synchronized indexers,and associated structure may be provided in order that the time intervalof stopping the conveyor may be minimized while at the same timepermitting such manifold assembly to be properly cycled. This of coursewould require proper timing of the various indexers in relation to thesynchronized drive.

It is to 'be understood in place of members 201, 202 and 203 forapplying the resin mixture to the support 200, resin mixture may beapplied as indicated with reference to FIGURE 6 and then heated.

Referring now in particular to FIGURES 21-25 inclusive, anotherembodiment of apparatus of this invention, generally designated 300 willnow be described. The apparatus 300 includes a generally rectangularframe having longitudinal frame members 301:1, and transverse framemembers 301b and 301C connected together at their ends to enclose thegenerally rectangular opening. Legs 302 are provided for supporting theaforementioned frame in an elevated condition.

Mounted by the frame for movement relative thereto and relative to eachother are a manifold assembly, generally designated 305; a heatedplaten, generally designated 306; and an alignment assembly generallydesignated 307. However other than for the differences notedhereinafter, the manifold assembly 305 is basically of the sameconstruction as the vacuum manifold assembly 35 which was described withreference to FIGURES 1-4. That is in referring to FIGURE 25, themanifold assembly 305 includes a manifold plate 310, a manifold body 311that in conjunction with the manifold plate provides a manifold chamber312, an apertured resilient pad 314 attached to the manifold plate bymanifold spools (not shown) which are mounted by the manifold plate in amanner illustrated in FIGURE 4, spacer rails 317 (see FIGURE 23), sideand end rails 313, peripheral resilient seal 315, angle brackets 318mounted by the manifold plate, and a perimetric, U-shaped channel 316bounded Aby bracket 318, the manifold plate, rails 313, 317 and seal315. Rails 313, 317 are secured to the manifold plate. Rails 317 do nothave lands 51a and are of a correspondingly smaller vertical thickness.The cross sectional area bounded by seal 315 may be less than twice aslarge as that bounded by rails 313.

Vertically extending reinforcing flanges 322 are attached to the side ofthe manifold body opposite the manifold plate, there being provided anelongated stop 323 attached to the reinforcing ange adjacent onetransverse edge of the manifold body to extend generally perpendicularthereto. The purpose of providing a stop will become more apparenthereinafter. Also attached to the opposite transverse edges of themanifold -body to extend outwardly therefrom are a plurality ofapertured guide lugs 324.

Fixedly attached to opposite longitudinal edges of the manifold body 311and frame 322 to extend outwardly therefrom are tubes 326 and 327respectively, the tubes in the manifold lowered position extendingthrough the centrally located, upwardly opening notches 303 in theframes. Since the structure for supporting tubes is the same, only thestructure for supporting tube 326 will be described (see FIGURE 23).

The tube 326 is rotatably extended through the annular mount 331 whichin turn is welded to the upper end of the piston rod 328 of the two wayacting piston cylinder combination generally designated 329. The pistoncylinder combination in turn is mounted on a plate 330 that extendsoutwardly from the frame and beneath tube 326. The cylinder ofcombination 329 is connected through uid lines 332 to a control valve(not shown) of a construction to alternately force the piston rod in thedirection of arrows 333, in a direction opposite 19 arrow 333, and toallow the piston and the structure mounted to move therewith to float Ononly tube 326, an annular member 335 is provided on the Outer endthereof, there also being provided a handle 336 having a bifurcated endportion pivotally mounted on pivot member 337 which is extended throughtube 326 and annular mount 335. Due to the aforementioned mounting ofthe handle it may be pivoted through an angle of 180 about an axisperpendicular to the transverse pivot axis of the tubes 326, 327 fromthe depending position illustrated in FIGURE 23 to a diametricallyopposite position. In order to releasably retain the manifold assemblyin a generally horizontal condition, a notched plate 339 is xedlyattached to the upper end of the cylinder, the handle being slideablypositionable in the notch which extends in a generally transversedirection. With the handle in the aforementioned notch, the tubes areprevented from rotating, however, upon the operator moving the handleabout the axis of pivot 337 in the direction of arrows 338 to a positionout of the notch, the manifold assembly may be pivoted.

In order to align the individual tile pieces 16 and move them to aposition to be picked up by the manifold assembly 305 there is providedthe alignment assembly 307 (see FIGURES 21 and 24). The assembly 307includes a heavy base plate 345 having an open perimetric frame 346 toextend thereabove, the frame being of a size to have the perimetric sealof the manifold assembly form a fluid seal therewith. Inside of theframe 346 and in abutting engagement therewith is a spacer frame 347bounding a rectangular opening. Located within the last mentionedopening and mounted on the base plate 345 is a rectangular constanttemperature member 349, there being provided electrical elements andcontrols (not shown) for retaining said member at a constanttemperature. Mounted to vertically move in the space between member 349and the spacer frame 347 is an alignment frame 348. The alignment frameis mounted in a manner such as described with reference to FIGURE 2 andis similarly resiliently retained in an upper position to extend abovethe vertically central portion of the tile pieces 116 positioned on theassembly 307 as will be described hereinafter. Advantageously a fabricpad or pads of substantial thickness may be overlaid on member 349. Inusing assembly 307 the tile mounting board having the tile piecesarrayed thereon as indicated with reference to FIGURE l is positionableon the pad 350 in order that the tile pieces may be aligned in themanner described with reference to FIGURE 2.

The assembly 307 in a datum position as illustrated in FIGURE 21 is justto the right of the manifold assembly 305 and longitudinally spacedtherefrom. In order that the assembly 307 may be transitorily moved to aposition just beneath the manifold assembly in an elevated condition, ahorizontal slide rail 353 is attached to each of the longitudinal framemembers to extend from a position adjacent to the heated platen 306 tothe transverse frame member 301e and at an elevation just beneath thelower horizontal edge of the notch 303. The alignment assembly includesa slide rail 354 secured to each longitudinal edge of the base plate 345and extends outwardly therefrom sufiiciently in order to slidablysupport said assembly on the rails 353.

In order to reciprocally move the assembly 307 from the positionillustrated in FIGURE 2l to a position directly beneath the manifoldassembly when the latter assembly is in an elevated position asillustrated in FIG- URE 24, a longitudinally extending two way actingpiston cylinder combination 356 has one end of the cylinder secured tocentral portion of the transverse frame member 301e` and the piston rodsecured to the plate 357 which at its upper end is welded to the edgeportion of the base plate 345 that is adjacent the manifold subassembly.Supply lines 358 are connected to the opposite ends of theaforementioned cylinder through an appropriate control valve to a sourceof air under pressure (not shown) for selectively actuating thecombination 356 to move the assembly 307 from the datum position (in thedirection of the arrow 360) to a position directly underlying themanifold assembly wherein the peripheral seal 315 is positioned directlyabove the perimetric frame 346; and thence 'back to the datum positionillustrated in FIGURES 21 and 22.

In order to align the manifold assembly in the aforementioned mannerwith the alignment assembly as the manifold assembly is lowered, guidelugs 361 having upwardly projecting pins 362 that are tapered at theirupper end are mounted outwardly of frame 346 to extend thereabove and tobe in alignment with the apertured lugs 324 of the assembly 305 in aposition rotated about the axis of the tubes 326, 327 from thatillustrated in FIG- URES 21 and assembly 307 beneath assembly 305 afterassembly 307 has been moved in the direction of arrow 360 by pistoncylinder combination 356.

The heated platen 306 includes a heated member 365 of a rectangularconfiguration and of an area substantially larger than the area of themanifold assembly. Member 365 includes a depending rectangular portion365 of about the same area as that enclosed 'by the outer vertical edgesof rails 313. The assemblies 305, 306 and 307 are of a construction toprovide a finished tile panel su-ch as described with reference toFIGURE 10.

Member 365 has a winding fluid channel 366 formed therein that at oneend opens through an outlet port to the flexible Huid line 368 which inturn is connected to an overhead steam or hot water supply line (notshown). The opposite end of channel 366 is connected through an outletport to one end of the rigid outlet line 369, the opposite end of line369 extending to an elevation beneath member 365 and is connected to aexible exhaust line (not shown). Controls (not shown) are provided tokeep the heated platen at a substantially constant temperature at alltimes that apparatus 300 is being used.

In order to move the rectngular member 365 from the datum positionillustrated in FIGURE 21 to a position directly above the manifoldassembly 305 when said assembly is in a lowered condition and rotated180 from that illustrated in FIGURE 21, there is provided a two wayacting piston cylinder combination 371 that has a piston rod connectedto the upwardly extending block 372. The lower end of the block iswelded to the top central edge portion of member 365 that is adjacentthe manifold assembly. The opposite end of combination 371 is lixedlyattached to the upright block 373, the lower end of said block beingsecured to transverse frame member 301b. Fluid supply lines 374 areconnected to the piston cylinder combination to selectively actuate thepiston thereof so that the rectangular plate 365 is moved in thedirection opposite arrow 360 to a position overlaying the manifoldassembly 305 and retracting said rectangular plate to the datumposition. The lines 374 extends through a control valve (not shown) to asource of air under pressure.

In order to facilitate the movement of the rectangular member 365relative to the frame, there are provided a plurality of depending wheelmounting blocks 376 at each longitudinal edge of the rectangular member365. Each wheel mounting block 376 mounts a wheel 377 to extendoutwardly therefrom and positioned to ride on the adjacent horizontaltrack 378, the tracks in turn being mounted on the longitudinal framemembers 301a to extend from a position adjacent the transverse rail 301bto a position adjacent the transverse edge of the manifold assemblywhich is closest to the alignment frame assembly. As may be noted inFIGURE 21 the tracks 378 are made of two pieces, the two pieces of eachtrack being spaced by a longitudinal dimension distance substantiallyequal to the longitudinal length of the respective notch 303. Eachlongitudinal side of member 365 has three wheels spaced similar to thatillustrated in FIGURE 21 such that it has two pair of wheels on trackportion 378a that will run over the respective tubular member 326, 327to the track portion 378b when the manifold assembly is in a loweredposition and the member 365 moved in the direction opposite arrow 360.The said two pair of wheels are longitudinally spaced a greater distancetherein the longitudinal length of a notch 303. Further the tracks areprovided with upwardly extending flanges to prevent the wheels runningoff the tracks after they have passed or are being passed over thetubular member 326, 327.

In order to control the application of air under pressure to themanifold chamber 312 and to the perimetric channel 316 there areprovided solenoid operated air control valves 381 and 380 that arerespectively mounted on the manifold body. Each of the valves 380, 381is located in a separate flexible uid supply line 386 that at one endopens through a connector 385 to the manifold chamber or perimetricchannel, passes through the respective control valve, and thence throughthe interior of the tubular member 327 to a source of air under pressure(not shown) Separate electrical control lines 379 are connected tovalves 380, 381 respectively and thence through tubular member 327 to asource of power and separate control switches (not shown).

In order to control the application of vacuum to the manifold chamberand the perimetric channel respectively there is provided solenoidoperated control valves 382 and 383 which are also mounted on the backside of the manifold body. A separate line 388 is provided for each ofthe valves 382, 383 that at at one end opens through a connector 384 tothe manifold chamber and perimetric channel respectively, then passesthrough respective valve 382, 383 and thence through the tubular member327 to a source of vacuum (not shown). Advantageous valves 44, 64, 69,72 and 380-383 may be such as those sold -by Barksdale Valves, LosAngles, Calif. model #1751 SOAC 2A1.

A vacuum gauge 390 is connected to a flexible line that passes throughtubular member 327 to a connector 394 that opens through the manifoldchamber to at all times indicate the negative pressure therein, if suchis the case. Likewise there is provided a connector 395 that opens tothe perimetric chamber and connected through a flexible line to thevacuum gauge 391 to indicate the negative pressure in said channel.Gauges 390, 391 are mounted on an instrument panel 393 which in turn ismounted on the tubular member 327 to rotate therewith.

In order to prevent the lines passing through tubular member 327 beingtwisted off, the stop 323 is provided to extend to an elevation suchthat upon rotating the manifold assembly from the datum position a fewdegrees in the direction opposite the arrow 375, the stop will abutagainst the heated platen to prevent further rotation, regardless if themanifold assembly is in its elevated condition or its datum condition asillustrated in FIGURES 2l and 22. Thus when the manifold assembly ispositioned in its datum condition it only can be rotated through ananglel80 in the direction of the arrow 375. Further the manifoldassembly in either an elevated condition or a datum condition cannot `berotated in the direction of arrows 375 through an angle of 360 since ifsuch were attempted, the stop 323 would engage the lower surface of theheated platen.

The structure of the apparatus of FIGURES 21-25 having been described,the operation thereof will now be set forth. In describing the operationof the apparatus, it will be assumed that said apparatus is in a datumcondition of FIGURES 21, 22 that no vacuum or air under pressure isbeing applied to the manifold channel or perimetric channel, and that notile mounting board has been positioned on the alignment assembly 307.In using the apparatus 300 a tile mounting board is positioned on avibratory mechanism 11 and individual tile pieces 16 arrayed thereonsuch as described with reference to FIG- URE 1. After tile pieces havebeen arrayed on the tile mounting board, the tile mounting board ispositioned on assembly 307 within frame 348, the tile pieces inspectedfor any imperfections (any imperfect tile pieces being replaced), andthe tile pieces on the peripheral edges of the board 10 wiped to abutagainst the alignment frame 348. Now the control valve of cylinder 329is operated to translationally elevate the manifold assembly in thedirection of arrows 333 from the position illustrated in FIGURE 21 tothe FIGURE 23 position.

After the manifold assembly has been elevated to the FIGURE 23 position,the controls for the piston cylinder combination 356 are operated suchtha air is supplied to the cylinder thereof to move the assembly 307 inthe direction of arrow 360 to a position that the assembly 307 islocated directly beneath the manifold assembly. At this time the controlfor piston cylinder combination 329 is operated to a oat condition andthereupon the manifold assembly lowers until the perimetric seal 315abuts against the perimetric frame 346. At this time the control for themanifold chamber vacuum control valve 382 is operated to withdraw airfrom the manifold chamber, and accordingly also from the perimetricchannel until the tile pieces form a seal with the resilient pad. Thatis normally when the seal 315 abuts against frame 346, there is leakageof air between the tile pieces and the spools such that air is withdrawnfrom the entire area bounded by seal 315 until such time seal 315 has`been suiciently compressed and the manifold plate moved downwardlyrelative the tile pieces to form a fluid seal with the resilient pad(see description relative FIGURES 11-14). Thus both vacuum gauges 390,391 initial indicate a drop in pressure. However at about 5-6 inches ofmercury, the last mentioned uid seal is formed and thence air is nolonger withdrawn from beneath the tile pieces and then from under rails313. Thus the channel gauge now indicates a constant pressure.

The pressure in the manifold chamber thence continues to drop from about5-6 inches of mercury to the desired pressure of about 2O inches ofmercury to rmly aiix the tile pieces to the manifold assembly, andthence the control for the perimetric channel control valve 380 isoperated to admit air under pressure to release the vacuum in saidchannel (return to atmospheric) as has been previously described withreference to the embodiments of the invention of FIGURES 1-5.

Now the manifold assembly is through piston cylinder combinations 329elevated and the combination 356 operated to retract the alignmentassembly to the datum position of FIGURES 21 and 22. With the manifoldassembly in an elevated condition, the handle 336 is pivoted in thedirection of arrow 338 out of the notch of the notched plate 339 andthence the handle rotated in the direction of arrow 375 to rotatetubular member 326 and the structure mounted by tubular members 326, 327through an angle of so that the resilient pad and tile pieces picked upby the manifold assembly face in an upward direction. The handle isreturned into the notch of the notched plate to prevent accidentalrotation of the manifold assembly. After the manifold assembly has beenthuS rotated the control for piston cylinder combination 329 is againoperated and the tubes 326, 327 are lowered to position such asillustrated in FIGURE 25, whereby the uppermost edges of the manifoldassembly are located at the lower elevation than the lowermost surfaceof the rectangular member 365 of the heated platen.

A pattern of an uncured resin mixture is applied to the tile pieces, forexample, a pattern such as illustrated with reference to FIGURE 6. Themixture may be applied by a hand held spray gun or an automaticdispenser that deposits a given volume of the mixture in the desiredpattern (with or without a pattern board). Now, advantageously, aclosely woven coated cloth `400 may be overlaid on the resin mixture,tile pieces and rails 313 to provide a good release from the cured resinmixture.

At this time the control for piston cylinder combination 371 is operatedwhereby the piston and piston rod thereof are extended to thereby movethe rectangular plate 365 to a position that is directly above themanifold assembly. Now the control of the piston cylinder combinations329 is operated such that combination 329 will raise the manifoldassembly to a position that the peripheral seal 31S abuts against therectangular plates 365 and lifts the heated platen sufficiently so thatthe wheels 377 are only slightly elevated off the track 378. Thereafterthe perimetric channel control valve 383 is operated to withdraw airfrom the perimetric channel until the gauge 391 reads approximately 13inches of mercury. The withdrawal of air from the perimetric channelresults the assemblies 306 and 305 moving more closely adjacent oneanother (the perimetric seal being compressed).

To be mentioned is that the drawing together of the platen and manifoldassembly due to the vacuum in the perimetric channel and the Weight ofthe platen acts through pad 400 and the uncured resin to the then topsurfaces of the tile pieces to depress said tile pieces, but still leavethe said top surfaces a few thousandths of an inch vertically higherthan the then top surface of rails 313 to provide vents to the jointspaces between the tile pieces. During this interval of time air iswithdrawn from the voids between the tile pieces and the rail 13 andalso pressure is exerted against the resin mixture to cause it to owinto said voids and form a backing over the top surfaces of the tilepiece (both due to the vacuum in the joint spaces and that resultingfrom the member 365 moving toward the manifold body). A small amount ofexcess resin usually will overrun the rails but there is left a thinlayer covering the then top surfaces of the tile pieces to form saidbacking player.

The assemblies 306, 307 are left at the 13 in. mercury position -untilthe time the resin has a chance to cure, which is a matter of a very fewminutes. Thereafter the controls for the vacuum valves 382, 383 areoperated to an olf position and the controls for valves 380, 381 areoperated so that air under pressure is applied to the manifold chamberand the perimetric channel such as described with reference to the firstembodiment. Thence the control of the piston cylinder combinations 329is operated such that tubes 326, 327 are moved to their lowermostposition with the assembly 305- out of contact with the assembly 306.This results in any elevated wheels 377 again engaging the tracks andthereafter the control for piston cylinder combination 371 is operatedto retract the rectangular plate 365 to a datum position. At this timethe coated cloth is removed, the ashing cleared off of the perimetricrails, and thence the tile panel which is of a construction describedwith reference to FIGURE l0, is removed from the manifold assembly.Advantag-eously a release agent may be sprayed on the then upwardsurface of the manifold assembly preparatory to making the next tilepanel.

Now the handle 36 is again rotated in the direction of the arrow 338 toclear the notch plate 339 and thence in the direction opposite of arrow375 to return said manifold assembly to the datum position of FIGURES 2land 22. The handle is then moved into the notch of plate 339.

Shortly before using the resin it is highly desired that it be degasedby being heated while being agitated at about 105 centigrade in a vacuumof about 28 in. of mercury for a period of about one hour.Advantageously the pigment may be added at this time.

In making the tile panels of this invention, it is preferred that theuncured resin have a viscosity in a range of 200G-35000 centipoise asmeasured by the Brookfield RVF viscometer using a #4 spindle at 20r.p.m. and 25 centigrade. lt is also preferred that the viscosity becloser to the 3500 centipoise end of the range. A suitable resin for theprocess is one sold under the trademark Urathox HCl775, of MinnesotaMining and Manufacturing. Another suitable resin is apolyesther-polyurethane elastomer sold by Chemical Products Corporationunder the trademark Chem-o-thane.

Using the resin Urathox or Chem-o-thane in accordance with thisinvention, it can be cured in about 3 minutes at C. for the purposes ofthis invention.

It is preferred that the resilient pad attached to the manifold be about5/16" thick and have a range of a durometer hardness of 15-25; that fortile pieces about 12716" sq. the cross sectional area of the unsupportedpad be about .3S-.50 square inch. (Le. that the area of the portion ofthe plate aperture directly above the resilient pad), and the manifoldpressure of about 18-24 inches of mercury; and that where the manifoldrails are not provided with lands the rails can be about .187 thick fora .217 inch thick tile piece.

As many widely apparent different embodiments of this invention may bemade Without departing from the spirit and scope thereof, it is to beunderstood that I do not limit myself to the specific embodimentsherein.

What I claim is:

1. In apparatus for making perforated tile panels comprising acontinuous conveyor having a pair of endless chains that have generallyhorizontal upper runs, means mounting said chains in transverse spacedrelationship including a driven shaft and a plurality of closely spacedtransversely elongated blocks mounted on said chains for movementtherewith, each of said blocks having a generally horizontal leg and arear vertical flange attached thereto of a smaller vertical dimensionthan the height of a tile piece, adjacent vertical surfaces on adjacentpair of blocks being longitudinally spaced a distance only slightlygreater than the length of a tile piece, means for delivering the tilepieces onto the horizontal legs of the blocks on the rearward portion ofsaid upper runs of the chains, elongated longitudinally extending meansextended above the block horizontal legs for properly transverselyspacing the tile pieces being carried by said blocks and means fordriving said driven shaft.

2. The apparatus of claim 1 further characterized in that there isprovided a manifold `body having a plenum recess therein, and a plateattached to said body to cover said recess, said plate having aplurality of apertures opening above a central portion of the tilepieces when properly spaced on said blocks, an apertured resilient mathaving a plurality of similarly spaced apertures attached to the side ofsaid plate opposite said body and means attached to said manifold bodyfor lowering said manifold body to position the resilient mat to abutagainst the properly spaced tile pieces on the blocks and applying avacuum to said recess through said apertures so that the tile piecescompress the mat and are aixed thereto, then raise the manifold bodytogether with the tile pieces andnext index the manifold body to alocation for further treatment, the last mentioned means beingsynchronized with the shaft drive means.

3. The apparatus of claim 2 further characterized in that there isprovided a support member and that the last mentioned means functions tolower the manifold body with picked up tile pieces unto said supportmember with the tile pieces in spaced relationship with the supportmember top surface.

4. The apparatus of claim 3 further characterized in that the supportmember has longitudinally and transverse extending grids insubstantially the same spaced relationship as the spacing 'between thetile pieces carried by the manifold body.

5. Apparatus for making preformed tile panels that include a pluralityof spaced tile pieces, a tile mounting board having transverse andlongitudinal grids to properly space the tile pieces, a resilient padhaving vertical aperture to open above the central portion of each tilepiece on said board to overlay the tile pieces on said board, a manifoldbacking plate to overlay said resilient pad and having an aperture toopen to each of said resilient pad apertures, and a manifold body joinedto said plate on the opposite side of said plate from said pad, saidplate and body cooperatively forming a manifold chamber that opens toeach of the plate apertures, and means for applying a vacuum to themanifold chamber whereby the tile pieces are caused to compress said padto deform portions of the pad into the spaces between the tile pieces.

6. The structure of claim further characterized in that each plateaperture has an enlarged diametric portion opening to the manifoldchamber and a reduced diameter portion opening to the adjacent padaperture and that a manifold spool is mounted in part in said plate andpad apertures, said spool having an enlarged diametric ange in saidenlarged diametric aperture portion, a reduced diametric portionextending through said reduced diametric aperture portion and theadjacent pad aperture and a ange underlying an annular pad portion, saidspool having a central aperture for applying a vacuum from the manifoldchamber to a tile piece.

7. The structure of claim 5 further characterized in that a manifoldspool is mounted in each plate aperture for limited axial movement, eachspool having an upper and lower flange, extended through a pad aperturewith the lower flange underlying the adjacent pad portion for retainingthe pad adjacent the manifold plate, and having a central aperture forconducting fluid between the manifold chamber and the area immediatelyadjacent the respective tile piece and that there is provided meansjoined to the manifold plate 4for mounting each spool for limited axialmovement relative the plate.

8. The structure of claim 5 further characterized in that there isprovided vibratory means for facilitating arraying of tile pieces onsaid mounting board, said vibratory means including a base forsupporting said mounting board and a perimetric frame on said lbasesurrounding said board and extending a substantial distance above saidboard when it is supported by the base.

9. The structure of claim 5 further characterized in that there isprovided an aligning platform for supporting said board and providing aborder surface against which the outer most rows of tile pieces on saidboard can be aligned, said platform including a base for supporting saidboard, a frame having a central opening of a size and shape to bound thetile pieces when spaced in accordance with the desired spacing in thefinished panel and means for mounting said frame in xed horizontalrelation to the base and limited vertical movement between a positionwith the upper horizontal surface substantial above the general uppersurface of the board on the base and a second position substantiallylower than the first mentioned position.

10. The structure of claim 5 further characterized in that spacers areprovided to surround said pad, rails to depend from the spacers, andmeans to mount said spacers and rails to the manifold plate to enclosecentral openings, the pad being located in the spacers center opening,the spacers being of approximately the same height as said pad and therails being of a substantial smaller height than the tile pieces, saidmanifold plate having a depending perimetric border member horizontalspaced from said rails and spacers to provide an open channel, saidperimetric border member depending to a lower elevation than said rails.

11. The structure of claim 9 further characterized in that said bordermember comprises a perimetric seal member and that there is providedmeans to apply a vacuum to said channel.

12. The structure of claim 11 further characterized in that there isprovided a support member having planar surface portions, said bordermember being of a dimension to vertically space the bottom surfaces ofthe tile pieces and rails above the planar portions when a vacuum isapplied to said channel and to said chamber to retain tile piecesadjacent said pad.

13. The structure of claim 11 further characterized in that said supportmember has upwardly extending grids separating said planar portions,said grids being vertically located between the tile pieces and of aheight approximately equal to said spacing between the tile pieces andthe planar portions.

14. The structure of claim 11 further characterized in that said supportmember includes means for applying heat to the top surface portionsthereof.

15. Apparatus for making preformed tile panels that include a pluralityof spaced tile pieces comprising a tile mounting board having atransverse and longitudinal grids to properly space the tile pieces, aresilient pad having vertical aperture to open above the central portionof each tile piece on said board to overlay the tile pieces on saidboard, a manifold backing plate having a general planar bottom surfaceto overlay said resilient pad and having an aperture to open to each ofsaid resilient pad apertures, and a manifold body joined to said plateon the opposite side of said plate from said pad, said plate and bodycooperatively forming a manifold chamber that opens to each of the plateapertures, and means for applying a vacuum to the manifold chamberwhereby the tile pieces are affixed against said pad to deform portionsof the pad into the spaces between the tile pieces, a resin mixturesupport member having a general planar support surface portion, saidsupport member and manifold having cooperating means forming aperipheral frame surrounding the tile pieces that are held adjacent theresilient pad by a vacuum applied through the manifold chamber andspacing said manifold plate surface portion above said support membersurface sufficient to indirectly support the tile pieces in verticalspaced relation to said support member.

16. The structure of claim 1S further characterized in that there isprovided means for applying a vacuum within said peripheral frame towithdraw air between the tile pieces and of negative pressure that thevacuum in the manifold chamber retains the tile pieces spaced above thesupport member.

17. Apparatus for making preformed tile panels that include a pluralityof tile pieces and cured resinous joints comprising means forfacilitating the arrayment of at least the majority of tile pieces inspaced relationship to provide joint spaces and supporting the arrayedtile pieces in an arrayed condition, a vacuum manifold assemblylowerable onto the arrayed tile pieces for picking up siad tile piecesin the arrayed condition, said assembly including a resilient pad andmeans for appling suction through said pad to the tile pieces for axingto said tile pieces on said arrayng means and releasably retaining saidtile pieces in the said relative relationship as arrayed, and means forsupportingly retaining an uncured resinous mixture and supporting saidmanifold assembly in a lowered condition, said manifold assembly anduncured resinous support means having cooperating means forming anenclosed chamber in which the tile pieces are located when afxed to saidresilient pad and the manifold assembly is lowered onto said resinoussupport means, and means connected to said cooperating means forselectively withdrawing air from said chamber and thereby cause uncuredresinous mixture on said support member to flow into the joint spacesbetween the tile pieces.

18. The structure of claim 17 further characterized in that saidarraying means includes an endless conveyor having transverselyelongated spacers for longitudinally spacing and supportingly conveyingtile pieces and mns cooperating with said conveyor for transverselyspacing said tile pieces.

19. The structure of claim 17 further characterized in that saidarraying means include a tile mounting board having cross intersectinggrids other than at the perimetric edges thereof and that there isprovided an alignment platform for aligning the outer most rows of tilepieces before said tile pieces are affixed to said manifold assembly,said alignment platform including a base for supporting said board,frame means enclosing a central opening and having inner verticalsurfaces against which the outer most rows of tile pieces on said boardcan be moved against to properly position the tile pieces in the outermost rows and an upper horizontal surface, and means connected to saidbase for mounting said frame means for limited vertical movement betweenan upper position where said horizontal surface is located at anelevation above the lower surfaces of the tile pieces on said board anda lower position.

20. The structure of claim 19 further characterized in that said fnamemounting means includes means for resiliently urging said frame means tosaid upper position and that said manifold assembly includes frame meanssurrounding said resilient pad for depressing said alignment frame meanswhen the manifold assembly is lowered unto said alignment platform, saidmanifold assembly frame means extending to a substantially lowerelevation than said pad.

21. The structure of claim 20 further characterized in that saidmanifold assembly and alignment platform having cooperating guide meansfor horizontally aligning one to the other as the manifold assembly islowered unto said platform and that said manifold assembly frame meansin a lowered condition has inner vertical surfaces that are spaced aboutone-half joint dimension from the respective outer most row of tilepieces that had abutted against said platform frame means.

22. The structure of claim 17 further characterized in that saidarraying means includes a horizontally vibratory base, a gridded tilemounting board removeably positionable on said vibratory base and aframe on said lbase to closely bound said board and extend above tilepieces deposited on said board.

23. The structure of claim 22 further characterized in that saidmanifold assembly includes a frame surrounding said resilient pad andextending to a lower elevation than the tile pieces affixed to said pad,said frame having xed depending lands with lower surfaces that abut saidresinous supporting means to limit the lowering of the assembly relativethereto and provide vents opening to the voids between the tile pieces.

24. The structure of claim 23 further characterized in that the manifoldcooperating means includes a depending resilient perimetric seal that ina relaxed condition extends to a substantially lower elevation than saidmanifold frame and surrounds said frame to in cooperation therewith forma perimetric channel that opens to said vents and means for applying avacuum to said channel.

25. The structure of claim 23 further characterized in that said landslimits the downwardly movement of said assembly on the resinous supportmeans to an amount that the tile pieces affixed to the resilient pad arevertically spaced from the last mentioned means.

26. The structure of claim 23 further characterized in that there isprovided a pattern board seatable on the resinous support means having acut out of an appropriate shape to have the resired quantity of uncuredresinous mixture deposited therein and to provide for the flow ofuncured resinous mixture to `spread over the en tire surface of saidresinous support means when the manifold assembly has been loweredthereon and a vacuum has been applied through said cooperating means.

27. Apparatus for making preformed tile panels that include a pluralityof spaced tile pieces, a tile mounting board having transverse andlongitudinal grids for properly spacing tile pieces, a manifold assemblyincluding a resilient pad having vertical apertures to open above thecentral portion of each tile piece on said board when located to overliethe tile pieces on said board, a manifold plate to overlie saidresilient -pad and having an aperture opening to each of the resilientpad apertures, and a manifold body joined to said plate on the oppositeside of said plate from said pad, said plate and body cooperativelyforming a manifold chamber that opens to each of the plate apertures, alongitudinally elongated frame, operable means for supportingly mountingthe manifold assembly on the frame for rotational movement about ahorizontal axis, and translating it relative to the frame between alowered and an elevated position relative to the frame, an alignmentassembly mounted on the frame for movement between a position underlyingthe manifold assembly when the last mentioned assembly is in an elevatedcondition anda lowered condition abutting against said alignmentassembly, and a retracted condition spaced from the manifold assemblysufficiently so that the manifold assembly may be rotated andtranslated, means connected to the frame and the alignment assembly formoving it between the two aforementioned positions, said alignmentassembly having means for receiving the tile mounting board and againstwhich the outer rows of the tile pieces on the tile mounting board maybe aligned and a heated platen mounted for movement on the frame betweena condition overlaying the manifold assembly in a lowered position and aretracted condition spaced from the manifold assembly, and means forselectively moving the alignment assembly between its positions, saidmanifold assembly having means for forming a perimetric channelincluding a peripheral seal for selectively abutting against thealignment frame and the heated platen, and means for selectivelyapplying a vacuum to the manifold chamber and thence through theresilient pad to the tile pieces to afx the tile pieces to said pad andto the perimetric channel when said peripheral seal abuts against theheated platen whereby air may be withdrawn from the voids between thetile pieces that are fixedI to the resilient pad.

28. The apparatus of claim 27 further characterized in that saidsupportingly mounting means include oppositely extending tubular membersthat are generally centrally located with reference to the longitudinallength of the frame, and that the operable means includes a pistoncylinder combination mounted by the frame directly beneath the tubularmembers, means connected to the piston cylinder combination to beelevated thereby for rotatably supporting said tubular members and meansconnected to one of said tubular members for selectively rotating saidtubular member through an angle of and locking the tubular members inits position after they have been rotated through an angle of 180.

29. Apparatus for making preformed tile panels that includes a pluralityof spaced tile pieces comprising a 1ongitudinally elongated frame, analignment assembly having a base plate, means mounted on the base platefor supporting tile pieces in an aligned condition and to facilitate thealignment of the outer rows of tile pieces, said base plate having ahorizontal cross sectional area substantially larger than that enclosedby said elongated frame, a manifold assembly including a resilient padhaving apertures to open above the central portion 0f each tile piece onsaid alignment means to overlie the tile pieces on said alignment means,means for mounting said resilient pad including means for selectivelyapplying a vacuum through each of said apertures, means cooperating withthe resilient pad mounting means for forming a perimetric channelsurrounding said resilient pad and spaced therefrom, a heated platen,means mounting said manifold assembly for transitorily movement andmovement through at least an angle of 180 about a horizontal axisrelative to the frame, means on the frame for mounting and moving thealignment assembly relative to the manifold assembly between a positionwherein the alignment frame assembly is spaced from the maniwherein thealignment frame assembly is spaced from the manifold assembly and in aposition that the alignment bly is directly beneath the manifoldassembly, and means on the frame for mounting and moving the heatedplaten

